Posts Tagged ‘makerbot’

Four Plans and a Ziggurat

June 28th, 2010

After we figured out how to greatly simplify our 3d models, Sara and I turned out attention to creating different levels of elevation. As a concept this is pretty simple; we used different brightnesses in areas of our 2d picture to tell Blender which shapes we wanted to be the highest, second highest, etcetera., all based on assigning thresholds of pixel value to different “z axis” numbers, which in Blender would become the elevation of the sprinkles.

Thrilled with our success for all of half a day or so, we quickly came to the realization that because we were using sprinkles (which are square), even with a wide range of elevation options, making a smooth hemisphere with the Cupcake would be almost impossible. It’d be like trying to create a pyramid or a dome and getting a ziggurat instead.

Ziggurat!

So we began brainstorming ideas for creating half a sphere over the surface of our model in Blender, using only the Python scripts. This was problematic to say the least because a) most of Blender’s power comes from the manipulatable interface of the model itself, as well as the hotkeys. Both of which are useless when scripting; and b) There is no “create half sphere” handy hotkey period, even if we could use them. In a fit of creative delusion, frustrated hair-pulling and occasional trips to the local icecream shop, we came up with four ideas. (The last one worked, in case you were panicking on our behalf.)

Idea 1 went something like this: “If we create a whole sphere (Blender lets us do this pretty easily) and chop it in half, we’ll have half a sphere!”   Not only did we fail to find a reasonable way of removing half a sphere’s vertices, but we also realized that we’d have to fill in the bottom of what would essentially be an overturned bowl shape. That idea was crossed out. I’m sure it’s possible to do, but our fate lay along a different path etcetera etcetera.

Idea 2: “There’s this cool modifier called ‘Subsurf’! It makes things all rounded!” I’m not quite sure why this one was a flop. I think it had something to do with my tendency to form vague ideas around nifty buttons in art programs.

Idea 3: “We could create branching arcs above the x-y plane, and just fill in the shell with vertices.” See “Idea 2”.

Idea 4 (The One That Worked): “Wait! Boolean expressions! Yes!”

The gist of what we ended up doing is that we realized boolean operations on different objects are pretty simple to script. Boolean options in Blender work just as they do in logic. “And”, “or”, and “not”. We used the Difference boolean operation on a cube and a whole sphere, after positioning them so that they overlap about halfway. What this did was create a sort of ghost mesh of a half-sphere, by telling Blender “remove all of object A that intersects with object B”. (“Difference” is the only Boolean operation in Blender where it matters what order you specify the two objects). So we ended up with a hemisphere (like we wanted), because the rest of that sphere shape overlapped with the dummy cube- which we deleted afterwards.

Some domes

Now that we could create rounded surfaces wherever we wanted; the next step was to let the user specify where they wanted them, using a GUI.

Printing Bug

March 5th, 2010

Prior to our successful (and very exciting) print the other night, we ran into a curious problem during print attempts. Namely, during the actual printing all the stages would suddenly stop but the Plastruder would continue emitting plastic. Here is an example of a failed attempt:

We even tried loading the model onto an SD card and building from the card. The same problem occurred. The interesting thing about this is that the print would stop in a random location each time. Finally, after digging around some forums for awhile, I found a post by someone suggesting a specific combination of versions for the software and firmware to use. With a lack of anything else to try, we decided to give it a shot. This involved downgrading the current versions of the software and firmware we were using. We then, with anticipation, attempted another print and, seemingly like magic, it worked!

Here is the list of software/firmware versions that we were using when our print was successful:

ReplicatorG 009
Skeinforge 005
Motherboard firmware 1.4
Extruder firmware 1.6

Heater Barrel Assembly (aka The Kapton Tape Experience)

January 26th, 2010

The next part of building the printer was putting together the heater barrel part of the Plastruder. The first step was to solder together the nichrome wire and the wire that will eventually connect the nichrome to the extruder controller. When we send electricity through the nichrome it will heat up, then heat up the heater barrel which it will be wrapped around and then heating the plastic that will run through the barrel. We also needed to older together the thermistor to the thermistor wires.

Next, we needed to wrap the nichrome wire around the threaded heater barrel, which is between the nozzle and the thermal barrier. We then attached the thermistor from the nozzle down the heater barrel. This step was all done with the help of our trusty friend Kapton tape. To insulate the heater barrel, we wrapped it with ceramic tape and then added a few more layers of Kapton tape, mostly to hold it all in place, but also because we just love it so much.

The next step was to add on the retainer washer. However, this involved unscrewing the barrier from the heater barrel. Somewhere in the process of unscrewing and rescrewing the barrier from the barrel, the nozzle came loose. This meant that we needed to unwrap all of our lovely Kapton tape, reset the nozzle and do it again. It slowed up progress for us and we recommend putting the retainer washer on in the beginning to avoid the possibility of having to redo it all.

Despite the little bump, we finished our heater barrel assembly. Here are some final pictures:

Heater Barrel Front

Heater Barrel Side

Circuit Boards

November 20th, 2009

During the past couple of weeks, Sara and I have been working on learning Blender and building our Cupcake 3D printer, pretty much simultaneously.  Recently we pulled together some of the chips that attach to our motherboard on the Cupcake, including an exciting field trip to find a vice in the Art department, and a thorough overturn of our box-o-parts to root out missing motherboard parts.  Which we didn’t find!  It was exciting.  The good news is that they’re tiny little bits that Professor Jadud probably has, so that isn’t really anything more than a hiccup.

We worked on the motherboard (or, more precisely, itemized the parts we were missing), the extruder control boards (three of them), and their corresponding stepper motors.  We also popped in the parts on the six opto endstops; they’re tiny little boards that still need to be soldered.

As far as Blender goes, we’ve essentially split the learning of it up into two approaches:  Sara’s tackling input scripting in Python and I’m working on going through all the settings and buttons and views and layers and lightings and angles and… well, you get the point.  Together we should be able to beat Blender into the dust.  Figuratively.  With.. you know, code.

Anyway, here are some pictures!  Complete with “Hippy Ribbon”, which is the endearing name in the Makerbot Cupcake’s tutorial for the rainbow wires.  The pictures are of an Extruder control, the Motherboard, and one of the Opto Endstops, respectively.

Extruder control

Motherboard (so far)
Optop Endstop